Segmented Amorphous Core Inductor for Vibration Reduction
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Solution Overview
Problem
Current inductor manufacturing faces challenges in achieving flexible form factors, robust configurations, high power and energy densities, tight inductance and Direct Current Resistance (DCR) tolerance, and consistent electrical and mechanical properties, especially in miniature structures, due to issues like core cracking, uneven winding, and high manufacturing costs.
Innovation Solution
The use of amorphous powder core materials for inductors, specifically iron-based or cobalt-based amorphous powder cores, with a distributed gap structure and preformed coils, along with a press molding process to create solid shaped-cores that reduce cracking and enhance permeability, allowing for tighter DCR control and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If toroidal cores are manufactured using amorphous powder material, then saturation current is improved, but manufacturing difficulty increases due to core cracking during winding
Solution Approach 1:
The patent divides the toroidal core into two separate shaped-core pieces (first shaped-core piece and second shaped-core piece) that are assembled together. This segmentation prevents cracking during winding because each piece can be independently formed and then joined, eliminating the manufacturing difficulty associated with winding on solid toroidal amorphous powder cores while maintaining the high saturation current performance.
Solution Approach 2:
The patent combines multiple manufacturing advantages by using amorphous powder material for the shaped-core pieces (improving saturation current) and then assembling them with a winding (solving the cracking issue). The combination of segmented shaped-cores with amorphous powder material creates a robust configuration that resolves both the reliability and manufacturability contradictions.
2Adaptability or versatility
If inductors are manufactured with hand winding, then flexibility is improved, but product consistency deteriorates
Solution Approach 1:
The patent uses preformed coils that are manufactured separately with controlled winding parameters before assembly. This preliminary action ensures consistent DCR and inductance values while maintaining design flexibility. The preformed coils are then assembled to the shaped-core pieces in a standardized process, eliminating the inconsistency of hand-winding while preserving adaptability.
3Quantity of substance
If inductors are miniaturized, then power density is improved, but manufacturing complexity increases
Solution Approach 1:
The segmented shaped-core design allows for miniaturization while simplifying manufacturing. Each shaped-core piece can be independently formed using press molding, which is more suitable for automated high-volume manufacturing than traditional methods. The assembly process of joining two pieces is simpler than attempting to wind coils on miniaturized toroidal cores, thus reducing manufacturing complexity while achieving high power density.
4Ease of manufacture
If discrete cores are assembled with gaps, then assembly is simplified, but inductance consistency deteriorates
Solution Approach 1:
The patent combines the first and second shaped-core pieces with the preformed coil in a single integrated assembly process. The coil is assembled to the shaped-core pieces such that there are no gaps between components, ensuring consistent magnetic path and inductance values. This merged configuration maintains assembly simplicity while achieving superior inductance consistency compared to gapped discrete core assemblies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in inductors with higher saturation flux density, wider operating frequency and temperature ranges, improved power and energy density, and tighter DCR tolerance, while minimizing size and acoustic noise, thus enhancing manufacturing efficiency and product reliability.
Implementation Method 1
amorphous powder core materials for inductors, specifically iron-based or cobalt-based amorphous powder cores, with a distributed gap structure
Implementation Method 2
amorphous powder core materials... with a distributed gap structure and preformed coils, along with a press molding process to create solid shaped-cores that reduce cracking and enhance permeability
Implementation Method 3
press molding process to create solid shaped-cores
Implementation Method 4
The inductors typically have a conductive winding wrapped around the core... The coil may be wound on the drum core or other bobbin core directly
Implementation Method 5
The inductors typically have a conductive winding wrapped around the core... Each end of the winding may be referred to as a lead and is used for coupling the inductor to an electrical circuit
Data Source
AI summary
A surface mount power inductor includes a preformed conductive winding clip and first and second-shaped core pieces. The core pieces may be configured to reduce unbalanced force experienced in the power inductor in certain types of power management circuitry. Reduction in the unbalanced force reduces vibration of the power inductor in use, and in turn reduces acoustic noise as the power inductor operates.